Air ionization systems and components

ABSTRACT

Ionization systems configured with a catalyst-bearing sleeve provide improved filtration while filtering ozone. Modular configurations provide for serviceability and replaceability. System controls may be used to monitor particulates, temperature, humidity, and other relevant factors and adjust an ionization level accordingly.

CROSS REFERENCE TO RELATED APPLICATIONS

This Application claims priority to U.S. patent application Ser. Nos.15/156,755, 15/156,735, and 15/156,771, all to Bender et al. and filedon May 17, 2016. The disclosures of these Applications are incorporatedherein by reference.

TECHNICAL FIELD

The present disclosure relates to air cleaning, and in particular to theremoval of particulates in air by utilizing ionization.

BACKGROUND

Prior approaches to air filtration and/or ionization suffer from variousdrawbacks. For example, certain air ionization systems, in order toavoid releasing an unacceptable level of ozone, generate ionizationlevels that are insufficient to fully clean and/or sanitize a particularair stream. Moreover, some air ionization systems have suffered from alack of configurability and/or intelligent control. Yet other airionization systems have been complex, expensive, and/or lacking inmodular configuration and/or serviceability. These and other drawbacksof prior approaches may remedied by principles of the presentdisclosure.

SUMMARY OF THE INVENTION

Disclosed are air ionization devices, systems, and methods that includean ozone dampening catalyst and an air ionization tube. The ozonedampening catalyst removes at least some of the ozone created byionizing molecules in the air. In one embodiment, rather than the airpassing by the ionization tube and being ionized in a known manner, airis drawn into an ionization module, and may pass through a filter thatmay be part of the module. The air then moves outward into a spacebetween the ionization tube and the ozone dampening catalyst, and it canbe pushed through the space by a fan. The air is ionized by theionization tube, which usually creates some ozone. The ozone ispartially or totally removed by the ozone absorption tube as the airpasses through it. Alternatively, the ozone dampening catalyst may be ina filter located at a position such that air passes the ionization tubeand is ionized, and then passes through the ozone dampening catalyst.The ozone dampening catalyst may be in a filter (which means anysuitable structure to permit air flow through and be exposed to thecatalyst) above, below or alongside of the ionization tube.

An air ionization unit is preferably an integral, one-piece unit, so itcan be removed from a surface to which it is mounted. That way it can bereplaced as a single unit without having to disassemble it. In onepreferred embodiment, the air ionization unit has a support plate thatmounts directly or indirectly to the outside surface of an airpassageway or other space (collectively, “duct”) that includes air to becleaned. The support plate is connected to a surface defining a duct byfasteners that pass through the support plate and through the materialof the surface duct. The air ionization tube and ozone dampeningcatalyst preferably are attached to and extend outward from the supportplate and into the air duct. The fasteners holding the support plate onthe exterior surface of the air duct can be removed to remove thesupport plate, air ionization tube and/or replace the entire airionization unit.

The invention may also include a controller that (1) measures the amountof particulate in the air, (2) measures the amount of negative and/orpositive ions in the air, (3) measures the amount of ozone in the air,(4) measures the amount of carbon monoxide in the air, (5) measures theair temperature and humidity, (6) measures the air flow rate through afilter, (7) adjusts the amount of ions being released into the air basedon one or more measured parameters, (8) displays one or more of themeasured parameters, and/or (9) provides an alert when a parameter is ata certain level.

Also disclosed are alternative ionization tubes and tube configurationsthat can be used to reduce the cross-sectional area in which the tube(s)are positioned and/or that provide greater ionization in the samecross-sectional area as known ionization tubes.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded view of an air ionization unit in accordance withembodiments of the invention.

FIG. 2 is an assembled, perspective side view of the air ionization unitof FIG. 1.

FIG. 3 is an assembled side view of the air ionization unit of FIG. 1.

FIG. 4 is a cross-sectional, side view of the air ionization unit ofFIG. 3 taken along lines A-A.

FIG. 5 is an end view of the air ionization unit of FIG. 3.

FIG. 6 is the opposite end view of the air ionization unit of FIG. 3.

FIG. 7 is an exploded view of an ozone dampening module according toaspects of the invention.

FIG. 8 is a perspective, side view of the assembled ozone dampeningmodule of FIG. 7.

FIG. 9 is an exploded view of an ionization module according to aspectsof the invention.

FIG. 10 is an assembled, perspective side view of the ionization moduleof FIG. 9.

FIG. 11 is an assembled, side view of the ionization module of FIG. 9.

FIG. 12 is a cross-sectional, side view of the ionization module of FIG.11 taken along lines A-A.

FIG. 13 is a rear, perspective view of a control unit according toaspects of the invention.

FIG. 14 is a front, perspective view of the control unit of FIG. 13.

FIG. 15 is a front view of the control unit of FIG. 13.

FIG. 16 is a side view of the control unit of FIG. 13.

FIG. 17 is a rear view of the control unit of FIG. 13.

FIG. 18 is a perspective, side view of an ionization system inaccordance with aspects of the invention with the housing opened.

FIG. 19 is a perspective, side view of the ionization system accordingto FIG. 18 with the control unit and energy converter removed.

FIG. 20 is a partial exploded view of the ionization system of FIG. 18showing the ionization module removed from the housing, and the housingremoved from a support plate.

FIG. 21 shows a front, perspective view of an ionization systemaccording to the invention.

FIG. 22 shows a display that may be used in accordance with aspects ofthe invention.

FIG. 23 shows a sensor that may be used in accordance with aspects ofthe invention.

FIG. 24 shows a helical ionization tube that may be used with aspects ofthe invention.

FIG. 24A is a top view of the tube shown in FIG. 24.

FIG. 24B is a side view of the tube shown in FIG. 24.

FIG. 24C is an alternative side view of the tube shown in FIG. 24.

FIG. 24D is a cross-sectional view of the tube of FIG. 24B along lineA-A.

FIG. 24E is an exploded view of this tube shown in FIG. 24.

FIG. 24F is an alternate example of an ionization tube that may be usedwith aspects of the invention.

FIGS. 25A-25C show alternate helical tubes that may be used with aspectsof the invention.

FIG. 26 shows an array of ionization tubes that may be used with aspectsof the invention.

FIG. 27 shows an air supply vent utilizing an ionization systemaccording to aspects of the invention.

FIG. 28 shows an intelligent filter monitor system and device accordingto aspects of the invention.

FIG. 29 shows a return air grill with a filter including an air flowsensor.

FIG. 30 shows a portable air ionization unit in accordance with aspectsof the invention.

FIG. 31A shows a side view of an alternative ozone removal assembly.

FIG. 31B shows a top view of the ozone removal assembly of FIG. 31A.

FIG. 32A shows a side view of an alternative ozone removal assembly.

FIG. 32B shows a top view of the ozone removal assembly of FIG. 32A.

FIG. 33 shows a side view of an alternative ozone removal assembly.

FIG. 34 shows a side view of an alternative ozone removal assembly.

DETAILED DESCRIPTION

The following description is of various exemplary embodiments only, andis not intended to limit the scope of the present disclosure in any way.As will become apparent, various changes may be made in the function andarrangement of the elements described in these embodiments withoutdeparting from the scope of the appended claims.

It should be noted that many alternative or additional functionalrelationships or physical connections may be present in a practicalionization system or related methods.

Turning now to FIGS. 1 through 6, a module 100 for ionizing air isshown. Module 100 as shown preferably has an end cap or “base” 102, anadapter 104, a coupler 106, an ion dispenser 108, a tube 110, an outerelectrode 112, and an inner electrode 114. Base 102 is preferablycomprised of any suitable plastic, for example injection-molded ABS (butpreferably not ABS-PC), although any suitable material may be used. Thepurpose of base 102 is to receive coupler 106, ion dispenser 108, andtube 110.

Coupler 106 has a first end 105, a second end 107, an outer surface106A, and a passageway 106B extending therethrough. In some embodiments,coupler 106 comprises a hollow aluminum rod. Moreover, coupler 106 maycomprise a solid bar with an internal thread on each end. Coupler 106may be configured to conduct electricity.

Adapter 104 as shown is a threaded shaft that bases through an opening(not shown in these Figures) of second end 118 of base 102 and isthreadingly received in a passageway 106B at the first end 105 ofcoupler 106. The opening in second end 118 may also be threaded so as tothreadingly receive adapter 104. In the preferred embodiment shown,adapter 104 is a threaded shaft with a first end 104A and a second end104B. A nut 104C is threadingly received on the threaded shaft end 105of coupler 106, which is aligned with the opening on the inside ofsecond end 118. First end 104A passes through the opening and isthreadingly received in passageway 106B of coupler 106 to retain coupler106 against second end 118. In some exemplary embodiments, adapter 104may comprise a solid stainless steel adapter with threaded ends and acentral integral hex feature to facilitate rotation thereof.

An ion dispenser (also called an “umbrella shaped conductor”) 108 isattached to second end 107 of coupler 106. In various exemplaryembodiments, ion dispenser 108 may be configured with an umbrella-likeshape. However, ion dispenser 108 may be configured with any suitableshape, as desired. Ion dispenser 108 operates to dispense electricityinto inner electrode 114. Ion dispenser 108 as shown in this preferredembodiment is comprised of stainless steel (for example, stainless steelhaving a thickness of between about 0.006 inches and about 0.015inches), has a top 108A for attachment to coupler 106, and a pluralityof downward extending fingers 108B. In this preferred embodiment, iondispenser 108 is attached to coupler 106 by aligning an opening in top108A with passageway 106B at end 107 of coupler 106. Then fastener 113,which as shown is a bolt, is passed through opening 108C and threadedinto passageway 106B. A lock washer 113A may be positioned between top108A and the head of fastener 113.

Inner electrode 114 typically comprises a rolled perforated aluminumsheet, but may comprise any suitable material or combination ofmaterials configured to act as a first electrode for purposes ofionization.

Outer electrode 112 typically comprises a tubular stainless steel wiremesh, for example a 0.008 in diameter Type 316 stainless steel wire meshconfigured with a 20×20 per square inch grid. However, outer electrode112 may comprise any suitable material or combination of materialsconfigured to act as a second electrode for purposes of ionization.

A tube 110 is preferably glass (for example, comprised of borosilicate)and retains coupler 106 and ion dispenser 108. Tube 110 is alsooperative to insulate inner electrode 114 from outer electrode 112 andthus permit the development of a voltage potential therebetween in orderto facilitate ionization. Tube 110 has a first, open end 110A, an outersurface 110B, and a second end 110C. Preferably, after cap 102, coupler106, and ion dispenser 108 are assembled, inner electrode 114 is placedwithin tube 110, the first end 110A of tube 110 is positioned over iondispenser 108 and coupler 106, and is received in cap 102 in a snug toslightly loose fit.

Outer electrode 112, which has a first end 112A, an outer surface 112B,a second end 112C, and an inner passage 112D, is positioned over tube110. In the preferred embodiment shown, outer electrode 112 does notcover second end 110C of tube 110 or extend to cap 102.

In the preferred embodiment, when module 100 is assembled, coupler 106and ion dispenser 108 are positioned approximately 50-60% inside thelength of tube 110, although any suitable percentage is acceptable. Inthis manner, electrical current is delivered to the inside of, andapproximately the center of, inner electrode 114.

With reference now to FIGS. 7 and 8, an ozone removal assembly 400comprises a tubular inner wall 406, a tubular outer wall 410, and a pairof ends 404. Inner wall 406, outer wall 410, and ends 404 may be coupledtogether to form a container for a catalyst media 408. In an exemplaryembodiment, inner wall 406 and outer wall 410 are coupled to a first end404 (for example, via RTV silicone). First end 404 is disposed on asurface, and the space between inner wall 406 and outer wall 410 isfilled with catalyst media 408. Second end 404 is then coupled to innerwall 406 and outer wall 410, securing catalyst media 408 in theresulting assembly. Inner wall 406 and outer wall 410 are configured tobe at least partially permeable to air. For example, inner wall 406 andouter wall 410 may comprise rolled stainless steel mesh screen or thelike.

In various exemplary embodiments, catalyst media 408 is configured toconvert, neutralize, and/or otherwise remove and/or reduce anundesirable compound in the air, for example ozone. Catalyst media 408may also be referred to as a “catalyst bed”, “reaction bed”, “ozonedestruction catalyst”, and/or the like. Catalyst media 408 may begranulated or otherwise shaped or formed to form part of ozone removalassembly 400. Catalyst media 408 typically comprises manganese dioxide,copper oxide, and/or the like, or combinations of the same. In someembodiments, catalyst media 408 comprises Carulite 200 offered by CamsCorporation (Peru, Ill.). However, any suitable catalyst configured toneutralize and/or remove ozone from an airstream may be utilized.

FIGS. 9 through 12 show an ionization and filter cartridge 200 accordingto a preferred embodiment of the invention. Cartridge 200 includespreviously described module 100. It also generally includes a housingand support structure, a fan assembly (or fan) 300, an ozone removalassembly 400, and an air filter 450. Air filter 450 may comprisepolypropylene, natural fibers, and/or the like. Air filter 450 isoperative to reduce the amount of dust and other airborne particulatesentering ozone removal assembly 400, as accumulation of dust on catalystmedia 408 reduces its efficacy.

The support structure of cartridge 200 includes a section for supportingmodule 100 and ozone removal assembly 400, and a section for supportingfan assembly 300, wherein in the preferred embodiment, when cartridge200 is fully assembled, it is a single unit that may be removed andreplaced when desired.

Turning now to FIGS. 13 through 23, an exemplary ionization andfiltration system 600 utilizes module 100 and cartridge 200. System 600further comprises electronic controls 500. In various exemplaryembodiments, electronic controls 500 are configured to control module100 to generate an ionization level in excess of 66% negative ions; anegative ionization level significantly higher than previous systems. Inthis manner, module 100 generates a net excess of negative ions, andthus improved air filtration and clearing is achieved. In contrast,prior ionization systems typically generated approximately 50% positiveions and 50% negative ions, thus achieving limited efficacy as many ionsquickly recombined and/or neutralized one another and were thus nolonger available for air filtration and clearing. In some exemplaryembodiments, electronic controls 500 pulse power convertors 520 in amanner suitable to positively bias power convertors 520 with respect tocircuit ground; this results in generation of excess negative ions inmodule 100.

Additionally, electronic controls 500 may further comprise and/orcommunicate with various inputs (e.g., sensors) which monitor ionizationlevels, the density of particulates in the air, the ambient humidity,temperature, and/or the like. Based at least in part on the sensorinputs, electronic controls 500 adjust the operation of system 600 toachieve a desired level of filtration, ionization level, and/or thelike.

With reference now to FIGS. 13 through 17, electronic controls 500typically comprise various electronic components, for example: a printedcircuit board; RF module 510 for wireless communication via a suitablewireless protocol or protocols (for example, IEEE 802.11 (“WiFi”), IEEE802.15.4 (“ZigBee”), Bluetooth, GSM, and/or the like); powerconvertor(s) 520 for creating, modulating, transforming, and/orconverting AC and/or DC current, for example for use in operating module100 to produce ions; wired communication and/or input programmingport(s) 530; together with various resistors, capacitors, inductors,transistors, diodes, light-emitting diodes, switches, traces, jumpers,fuses, amplifiers, antennas, and so forth as are known in the art. Invarious exemplary embodiments, electronic controls 500 further comprisea microprocessor and/or microcontroller (for example, an 8-bit or 16-bitmicrocontroller, such as the PIC16F1503T-I/SL microcontroller offered byMicroChip Corporation of Chandler, Ariz.). The microcontroller isoperative for algorithmic (e.g., pre-programmed) operation, as well asresponsive (e.g., pursuant to sensor inputs, communications, etc.)operation of system 600.

In one operating mode, electronic controls 500 are configured to operatemodule 100 at an 80% duty cycle (for example, 4 minutes in an iongeneration mode, followed by one minute powered down, followed by 4minutes in an ion generation mode, and so forth). In another operatingmode, electronic controls 500 are configured to operate module 100 at a100% duty cycle (always on). However, any suitable duty cycle may beutilized.

In various exemplary embodiments, electronic controls 500 are configuredto generate up to 6000 volts at frequencies between 1 kHz and 2 kHz foruse in ionization. Electronic controls 500 typically draw between about700 milliamps and about 900 milliamps. Power supplied to module 100 viaelectronic controls 500 may be digitally managed, for example via apulse width modulation (PWM) technique utilizing a fixed voltage andvariable duty cycle. Moreover, operating parameters for electroniccontrols 500 may be remotely managed.

In various exemplary embodiments, electronic controls 500 employ a“white noise” mode wherein power convertors 520 are turned on and/or offvia randomized timing. In this manner, transformer “whine” or “powerline hum” may be reduced and/or eliminated, making the resulting systemquieter and/or more suitable for indoor use.

In yet another operating mode, electronic controls 500 are configured tooperate system 600 in an “ozone depletion mode” whereby module 100 ispowered down and does not create ionization, but air is still passedthrough catalyst media 408, for example responsive to operation of fanassembly 100 (and/or as a result of ambient airstream movement, forexample in an HVAC duct). In this manner, system 600 is operative toremove ozone from the ambient air.

In various exemplary embodiments, electronic controls 500 monitor theperformance of module 100 and/or ozone removal assembly 400, and maysignal when a component of system 600 needs replacing (for example, dueto deterioration of ionization components in module 100, due to dustaccumulation on catalyst media 408 in module 400, and/or the like).

Electronic controls 500 are configured to monitor and control variousoperational characteristics of system 600, for example for safety. Invarious embodiments, electronic controls 500 monitor fan 300 speed andcurrent draw, as well as module 100 voltage and current draw. System 600may be shut down and/or restarted if an anomaly is detected.Additionally, electronic controls 500 may monitor status and errorconditions, turn an ozone depletion mode on or off, monitor temperaturelimits for operation, and/or adjust a duty cycle associated withoperation of module 100.

With reference now to FIGS. 18 through 21, system 600 may be configuredto be installed in a ventilation duct, for example an existing HVAC ductof a building. System 600 may be installed in connection with a newbuild, or as a retrofit.

While various exemplary embodiments of system 600 may be discussed inthe context of a residential HVAC installation, it will be appreciatedthat embodiments of the invention may be deployed in a wide variety ofform factors, installation locations, and uses. For example, system 600may be configured as: a desktop unit for placing on an office desk; afreestanding unit (for example, similar in form factor to a tower-stylefan); a unit for installation in a vehicle such as an automobile, bus,or airplane; or a high-volume unit for use in connection with ahospital, school, food processing plant, restaurant, and/or the like. Inparticular, system 600 may desirably be utilized to sanitize anddeodorize air that is exposed to or contains strong- smelling organiccontaminants, reducing and/or eliminating undesirable odors.

In some embodiments, with reference to FIG. 22 system 600 may furthercomprise a control panel 700. Control panel 700 comprises a display andvarious inputs, buttons, and the like. Control panel 700 is in wiredand/or wireless communication with control electronics 500. Via controlpanel 700, a user may view statistics regarding operation of system 600,give commands to system 600, view error messages or other system 600communications, and the like.

In various embodiments, with reference to FIG. 23 system 600 may furthercomprise one or more remote sensors 800. Remote sensor 800 is in wiredand/or wireless communication with control electronics 500. Remotesensor 800 comprises various sensors, for example a temperature sensor,particulate sensor, ozone sensor, carbon monoxide sensor, humiditysensor, and/or the like. Responsive to information received from remotesensor 800, control electronics 500 may modify operation of system 600,for example turning module 100 on or off, turning fan 300 on or off,and/or the like. For example, when remote sensor 800 reports ambientozone above a target threshold, control electronics 500 may operatesystem 600 in an ozone depletion mode for a period of time until ambientozone is below a target threshold. Likewise, when remote sensor 800reports that particulates are above a target threshold, controlelectronics 500 may increase the duty cycle of module 100 in order togenerate increased ionization and thus increase the rate of particulateremoval. Remote sensor 800 may be battery powered, or may be configuredto be plugged into a power outlet. Multiple sensors 800 may be utilizedto provide information regarding an operational environment to controlelectronics 500.

In various exemplary embodiments, operating parameters for system 600may be monitored and changed remotely, for example via wirelesscommunication. Changes for system 600 may be supplied via a connectedsoftware application operable on a tablet or smartphone, via controlpanel 700, via a universal serial bus connection to control electronics500, and/or the like.

Alternate Module Configurations for Ionizing Air

Any of the alternative module configurations described herein may beused in systems or devices as previously described, or as describedbelow. The alternative module configurations function in the same mannerand have the same components as module 100, but they have differentshapes, and/or different configurations, which makes them better suitedfor certain uses.

FIG. 24 shows a curved, or semicircular, module 1500. Module 1500 hasthe same components as module 100, except that some are shaped, andpotentially sized, differently. Module 1500 has two end caps 1502 and1504. Module 1500 has an adapter 1508 (which is the same as previouslydescribed adaptor 104), a curved coupler 1512 (which functions in thesame manner as previously-described straight coupler 106), an iondispenser 1514 (which functions in the same manner and has the samedesign and sub-structures as previously-described ion dispenser 108), atube 1506 (which is formed of the same material and functions in thesame manner as previously-described tube 110), an outer electrode 1516and an inner electrode 1518 (which, other than their shape, arepositioned, and function, respectively, in the same manner aspreviously-described outer electrode 112 and inner electrode 114).

End caps 1502, 1504 are preferably comprised of any suitable material,such as injection-molded ABS. Cap 1504 has the same structure aspreviously-described cap 102, and receives and supports coupler 1512,ion dispenser 1514, and tube 1506.

Coupler 1512 has a first end 1505, a second end 1507, an outer surface1512A, and a passageway 1512B extending therethrough. In someembodiments, coupler 1512 comprises a hollow aluminum rod. Coupler 1512may instead be a solid bar (which could comprise aluminum) with aninternal threaded bore on each end to attach to other structures.Coupler 1512 may conduct electricity, and preferably does.

Adaptor 1508 as shown is a threaded shaft that passes through an opening(best seen in FIG. 24D) and is threadingly received in a passageway1521, preferably in the same manner as threaded shaft 104 is attached tomodule 100.

An ion dispenser 1514 is attached to second end 1507 of coupler 1512. Inan exemplary embodiment, ion dispenser 1514 may be configured with anumbrella-like shape, such as the shape of ion dispenser 108. However,ion dispenser 1514 may be configured with any suitable shape, asdesired. Ion dispenser 1514 operates to dispense electricity to innerelectrode 1518. Ion dispenser 1514 as shown in this preferred embodimentis comprised of stainless steel (for example, stainless steel having athickness of between about 0.006 inches and about 0.015 inches), andpreferably has the same structures and materials as previously-describedion dispenser 108, and is attached to coupler 1512 in the same manner asion dispenser 108 is attached to coupler 106.

Inner electrode 1518 typically comprises a rolled perforated aluminumsheet, but may comprise any suitable material or combination ofmaterials configured to act as a first electrode for purposes ofionization.

Outer electrode 1516 typically comprises a tubular stainless steel wiremesh, for example a 0.008 in diameter Type 316 stainless steel wire meshconfigured with a 20×20 per square inch grid. However, outer electrode1516 may comprise any suitable material or combination of materialsconfigured to act as a second electrode for purposes of ionization.

A tube 1506 is preferably glass (for example, comprised of borosilicate)and retains coupler 1512, and ion dispenser 1514, and inner electrode1518. Tube 1506 is also operative to insulate inner electrode 1518 fromouter electrode 1516 and thus permit the development of a voltagepotential therebetween in order to facilitate ionization. Tube 1506 hasa first, open end 1505, a second, open end 1509, and an outer surface.Preferably, after cap 1504, coupler 1512, and ion dispenser 1514 areassembled, inner electrode 1518 is placed within tube 1506, the firstend 1505 of tube 1506 is positioned over ion dispenser 1514 and coupler1512, and is received in cap 1504 in a snug to slightly loose fit.

Outer electrode 1516, which has a first end 1516A, an outer surface1516B, a second end 1516C, and an inner passage into which tube 1506 isreceived, is positioned over tube 1506. In the preferred embodimentshown, outer electrode 1516 does not cover second end 1509 of tube 1506or extend to cap 1504.

In the preferred embodiment, when module 1500 is assembled, coupler 1512and ion dispenser 1514 are positioned approximately 30-50% inside oftube 1506, although any suitable percentage is acceptable. In thismanner, electrical current is delivered to the inside of, andapproximately the center of, inner electrode 1518.

Ion dispenser 1514 is preferably connected to a second end 1507 ofcoupler 1512 and functions in the same manner, and is preferably formedof the same material, as ion dispenser 108.

Module 1500 is curved and to accommodate this curved shape, tube 1506,coupler 1512, inner electrode 1518 and outer electrode 1516 are suitablycurved. Module 1500 includes a first end sleeve 1502, a second endsleeve 1504 and a curved body portion 1506. A connector 1508 isconfigured to connect to a power source (not shown). End sleeve 1502(previously described) has a fastener 1510, which has the same structureand is utilized with the same components as fastener 113.

The coupler 1512, which functions in the same manner as coupler 106, isconfigured so it has a curve that approximates or is equal to the curveof tube 1506, so that coupler 1512 is approximately centered, orcentered, in curved tube 1506.

Ionization module 1500 may be in the shape of a continuous curve, or bestraight along the central portion 1506A and have curves at sideportions 1506B, as shown in FIG. 24F. Further, ends 1506C of tube 1506may be straight or curved. If curved, end sleeves 1502 and 1504 areconfigured in a shape to fit on curved ends 1505 and 1509.

FIG. 24A shows a top view of ionization module 1500. FIG. 24B shows aside view of ionization module 1500. FIG. 24C is an alternate side viewof ionization module 1500. FIG. 24D is a cross-sectional top view ofmodule 1500 taken across line A-A of FIG. 24B. FIG. 24E is an explodedview of ionization module 1500. Not shown in FIGS. 24-24F is an ozoneremoval assembly, which is the same type of assembly aspreviously-described assembly 400 except that it would be shaped to fitat least partially over ionization module 1500 or 1500′ and allow aspace therebetween for air to pass through. Alternatively, as describedbelow, the ozone dampening catalyst could be in a filter of any shape orsize wherein the ionized air passes through the ozone dampening catalystafter it is ionized by the ionization module.

A tube 1500′ with a straight section 1506A, curved side sections 1506B′,and end sections 1506C′ is shown in FIG. 24F. Coupler 1512′ isconfigured to fit in tube 1506′ so it is approximately centered orcentered inside of tube 1506′. Ion dispenser 1514′ is the same as iondispenser 1514 shown in FIG. 24, which is the same as ion dispenser 108.End caps 1502′, 1504′ are configured to fit on straight end sections1506C′ of tube 1506′.

An advantage of making an ionization tube in one of these shapes is thattube 1500 or 1500′ can have the same total area for ionization as for astraight tube, it can fit inside a smaller, or differently-sized,structure or space. Alternatively, it can provide a greater ionizationarea within the same space.

FIG. 25A shows a helical, multi-twist tube 1600 with a constantdiameter. Tube 1600 has a body 1602 that includes an end 1604, an end1606, two full coils 1612, and two partial coils 1608 and 1610. End caps(not shown), internal ionization structures (not shown), inner and outerelectrodes (not shown), and an ozone removal assembly (not shown), areconfigured and sized to function with tube 1600 in the same preferredmanner as described herein. As an example, the coupler and ion dispensermay be inserted through end 1604 or 1606, and may be positioned in up to20%-60% of the length (as measured annularly) of tube 1600.

FIG. 25B shows a helical, multi-twist tube 1650 with a decreasingdiameter moving from end 1656 to end 1654, which is also referred toherein as an inward helical shape. Tube 1650 has a body 1652 thatincludes an end 1654, an end 1656, two full coils 1662, and two partialcoils 1658 and 1660. End caps (not shown), internal ionizationstructures (not shown), inner and outer electrodes (not shown), and anozone removal assembly (not shown), are configured and sized to functionwith tube 1680 in the same manner as described herein, although thesecomponents would be configured to fit on or in tube 1650, or tootherwise function with tube 1650. As an example, the coupler and iondispenser may be inserted through end 1654 or end 1656 and may bepositioned in up to 20%-60% of the length (as measured annularly) oftube 1650.

FIG. 25C shows a helical, multi-twist tube 1680 with an increasingdiameter moving from end 1686 to 1684, which is also referred to hereinas an outward helical shape. Tube 1680 has a body 1682 that includes anend 1684, an end 1686, two full coils 1692, and two partial coils 1688and 1690. End caps (not shown), internal ionization structures (notshown), inner and outer electrodes (not shown), and an ozone removalassembly (not shown), are configured and sized to function with tube1680 in the same manner as described herein, although these componentsare configured to fit on or in tube 1680, or to otherwise function withtube 1680.

FIG. 26 shows a rotary configuration 1700 of multiple (or a pluralityof) straight ionization modules 1702. Each module 1702 has any suitablestructure, such as the preferred structure of previously-describedmodule 110, with ion dispenser 108, inner electrode 114, coupler 106,outer electrode 112, cap 102, and ozone removal assembly 400. Althoughsix tubes 702 are shown, any plurality of tubes, such as between threeand eight tubes, can be arranged in a rotary configuration. An advantageof this configuration is that a greater overall tube surface area, andhence ionization area, is provided in a given space. In addition, eachindividual tube could have a length and/or diameter that is less thanthat of a standard ionization tube. For example, each tube may have alength of anywhere between 4″ and 12″; or up to 4″, 5″, 6″, 7″, 8″, 9″,10″, 11″, or 12″; or a length greater than 12″. Each tube may also havean inner diameter of anywhere between ¼″ to 1½″; or up to ¼″, ½″, ¾″,1″, 1¼″, 1½″, 1¾″, 2″, 2¼″, or 2½″; or greater than 2½″. Additionally,tubes used in configuration 1700 may have differing lengths and innerdiameters.

Additionally, the ozone removal assemblies 400 on each tube 1702 couldinstead, or in addition to, be an ozone removal filter (such as filter1780, described below), which could be below, above or beside tubes1702, or that is otherwise downstream of the tubes 1702 according to thedirection of the flow of air being ionized.

Supply Air Vent

FIG. 27 shows a supply air vent 1750 with an integral air ionizationsystem. As shown, supply air vent 1750 has (1) a clean air filter 1760(which is optional and need not be used); (2) an ionization module 1770,which as shown is a curved ionization unit, such as previously-describedmodule 1500, but could be any suitable ionization module, such as module1600, 1650, or 1680, or a single, straight module 110, or a plurality ofstraight modules 1702 in a rotary configuration as shown in FIG. 26, ora plurality of straight tubes placed side to side or in any suitableposition; (3) an ozone removal filter 1780 beneath ionization unit 1770;and (4) vent frame 1790, which is configured to retain structures 1760,1770, and 1780 and be mounted in an air supply vent. The ozone removalfilter is shown as being flat, but it preferably has the same structureas defined for ozone removal assembly 400 and includes catalyst media408, as previously described.

An optional fan (not shown) may be positioned between the clean airfilter 1760 and ionization unit 1770, or above clean air filter 1760, orif there is no clear air filter 1760, above the ionization module 1770.If used, the fan is positioned and configured to push air pastionization unit 1770 and through ozone removal filter 1780, which is thenormal flow of air through the air supply vent cover 1750 into a livingor working space.

Airflow Sensors

FIG. 28 shows an ionization module 1800, which is the same as removablemodule 100 previously described. Module 1800, however, includes airflowsensors, which are known in the art, that detect the flow of air intothe space between the ionization tube and the ozone filter. Based on thedifference between the air flow rate at the time module 1800 is firstinstalled and a current air flow rate, the air flow sensor can signalthe controller and the controller can initiate an alert that the cleanair filter (or preferably the entire ionization module 1800 should bechanged). The alert could be noise, such as a “beep” recurring at settime intervals (such as any interval between five minutes and one hour.Or, the alert may be a continuous or flashing light signal or display ofthe control panel, such as lighted words that read “change filter,” or“change ionization module.” Accordingly, the controller must beprogrammed to include in it an air-flow rate that indicates replacementof an air filter, or assembly including and air filter, is required.This air-flow rate is determined by one or more of several factors for agiven environment: (1) whether smokers are present and how much theysmoke, (2) where the filter is located, such as in the kitchen (wherethere are many contaminants, or in a remote bedroom that's seldom used,(3) whether there are pets in the building and where the pets arelocated, (4) the number of occupants in the building, (5) activities inthe building that would create particulates, and (6) the type of HVACsystem used. In other words, instead of changing air filters based on aset period of time, the variables above would be entered into thecontroller and the controller would create an alert to change a filterwhen the air-flow rate is at a predetermined level that indicates thefilter should be changed.

A filter such as filter 1760 or 1780 could also have associated air-flowsensors located at any suitable position (such as one or more at or nearthe center of the filter, plus additionally others on one or more sidesand corners of the air filter) to detect when clean air filter 1760 orozone removal filter 1780 should be changed. Such air-flow sensors, whenthey detect the air-flow through a filter is at too low a rate, couldsignal the controller, which could create an alert, preferably in one ofthe ways previously described.

FIG. 29 shows a return air grill 1850 with a grill 1860 and one or morefilters 1870. In the embodiment shown, the filters are monitored byair-flow sensors in one of the ways previously described.

Portable Unit

FIG. 30 shows a portable ionization unit 900 that utilizes ionizationair cleaning according to the invention. Unit 1900 is portable and canbe moved from room to room or building to building. It can be smallenough to fit into a suitcase. Unit 1900 ionizes air in one of themanners previously described and otherwise functions in a mannerpreviously described.

Alternate Ozone Removal Assembly Configurations

Any module, such as module 100, 1500, 1500′, 1600, 1650, 1680, 1700,1770, or 1800 could have any suitable clean air filter size orconfiguration (which are optional, but preferred) and also any suitableozone removal assembly size or configuration, as long as the ionized airpasses through the ozone removal assembly after being ionized. FIGS.31-34 show various structures of ozone removal assemblies that may beutilized with one or more ionization module(s), it being understood thatany suitable ozone removal assembly structure or ionization module maybe utilized.

FIG. 31 shows an ozone removal assembly 3100 having a rectangular shapewith an open top. Assembly 3100 has four sides 3100A, 3100B, 3100C,3100E, a bottom 3100F, and an inner cavity 3100D. One or more ionizationmodules are preferably positioned in cavity 3100D. Air flows into cavity3100D past the one or more ionization units and passes through bottom3100F and/or sides 3100A, 3100B, 3100C and 3100E, one or more of whichinclude ozone dampening catalyst to reduce ozone.

FIG. 32 shows an ozone removal assembly 3200 that is the same asassembly 3100 except that instead of having an open top, it has anopening 3200E in top surface 3200F through which air flows. Assembly3200 has four sides 3200A, 3200B, 3200C, and 3200D. It also has a bottom3200G, and a top 3200F having opening 3200E. A cavity 3200H preferablycontains one or more ionization modules. Air flows into cavity 3200Hthrough opening 3200E and is ionized. It then flows outward through oneor more of walls 3200A, 3200B, 3200C, 3200D, 3200F, and 3200G, one ormore of which includes ozone dampening catalyst.

FIG. 33 shows a curved ozone removal assembly 3300 on the side of one ormore ionization modules. Air is flowed past the one or more ionizationmodules and then passes through ozone removal assembly 3300.

FIG. 34 shows a curved ozone removal assembly 3400 beneath one or moreionization modules. Air is flowed past the one or more ionizationmodules and then passes through ozone removal assembly 3400.

As used herein, the terms “comprises,” “comprising,” or any othervariation thereof, are intended to cover a non-exclusive inclusion, suchthat a process, method, article, or apparatus that comprises a list oflimitations does not include only those elements but may include otherlimitations not expressly listed to such process, method, article, orapparatus. Also, as used herein, the terms “coupled,” “coupling,” or anyother variation thereof, are intended to cover a physical connection, anelectrical connection, a magnetic connection, an optical connection, acommunicative connection, a functional connection, and/or any otherconnection. The word “exemplary” is used herein to mean “serving as anexample, instance or illustration”. Any embodiment described as“exemplary” is not necessarily to be construed as preferred oradvantageous over other embodiments and/or to exclude the incorporationof features from other embodiments.

Having thus described some embodiments of the invention, othervariations and embodiments that do not depart from the spirit of theinvention will become apparent to those skilled in the art. The scope ofthe present invention is thus not limited to any particular embodiment,but is instead set forth in the appended claims and the legalequivalents thereof. Unless expressly stated in the written descriptionor claims, the steps of any method recited in the claims may beperformed in any order capable of yielding the desired result.

What is claimed is:
 1. An air ionization system, comprising: (a) An airsupply duct frame configured to fit into a supply air duct, the airsupply duct including a cavity; (b) one or more ion generators togenerate ions, and that generate more negative ions than positive ions,wherein the one or more ion generators are positioned in the cavity; and(c) an ozone removal assembly positioned in the cavity beneath the oneor more ion generators, the ozone removal assembly containing a catalystmedia for removal of ozone from air, the air passing through the ozoneremoval assembly after the air passes the one or more ion generators. 2.The air ionization system of claim 1, wherein the air supply duct frame,one or more ion generators and ozone removal assembly form a modularunit configured to be removed from the air supply duct and replaced as asingle unit.
 3. The air ionization system of claim 1, wherein the one ormore ion generators comprises one curved tube with a single wind.
 4. Theair ionization system of claim 1, wherein the one or more ion generatorscomprises a tube with two full winds and two partial winds.
 5. The airionization system of claim 1, wherein the one or more ion generatorscomprises a plurality of straight ionization modules arranged end-to-endin a circular pattern.
 6. The air ionization system of claim 5 thatincludes between three and six ionization modules.
 7. The air ionizationsystem of claim 5, wherein there are six ionization modules.
 8. The airionization system of claim 1, wherein the ozone removal assembly is partof a flat filter underneath the one or more ion generators.
 9. The airionization system of claim 1 that further includes a clean air filter inthe cavity and above the one or more ion generators.
 10. The airionization system of claim 9, wherein the clean air filter includes oneor more airflow sensors in communication with the control system,wherein the airflow sensors sense the rate of airflow through the cleanair filter.
 11. The air ionization system of claim 10, wherein thecontrol system detects when the clean air filter should be changed basedon the airflow through the clean air filter.
 12. The air ionizationsystem of claim 11, wherein the control system creates an alert when theclean air filter should be changed.
 13. The air ionization system ofclaim 12, wherein the alert is a light on a display of the controlsystem.
 14. The air ionization system of claim 1, wherein the ozoneremoval assembly at least partially surrounds the one or more iongenerators.
 15. The air ionization system of claim 1, wherein the ozoneremoval assembly completely surrounds the one or more ion generators.16. The air ionization system of claim 14, wherein the ozone removalassembly shape is selected from one or more of the group consisting of:round, square, rectangular, five- sided, four-sided, three-sided,two-sided, one-sided, semi-circular, or a curved wall.
 17. The airionization system of claim 1 that further comprising a fan in thecavity, the fan disposed between the clean air filter and the one ormore ion generators.
 18. The air ionization system of claim 1, whereinthe ozone removal assembly further comprises: (a) an inner stainlesssteel mesh screen forming a first tube; (b) an outer stainless steelmesh screen forming a second tube; (c) a pair of end caps coupling thefirst tube and the second tube; and (d) the catalyst media is disposedat least partially between the first tube and the second tube.